HEADRUSH ZSIR150-20A Instruction manual

ZIPSTOP
ZIP LINE
BRAKE
Installation, Operation & Maintenance Manual
Models: ZS125-08 / ZSIR150-20A
NOTE TO INSTALLERS
Always Read Instructions Before Use
Leave this manual attached to the zipSTOP Brake unit. The Installation, Operation
and Maintenance manual contains information relating to the proper use of the
zipSTOP and includes all product registration and warranty information. This doc-
ument may only be removed by the end user prior to operation. Ensure that this
manual is readily available to operators at all times.
Head Rush Technologies zipSTOP Zip Line Brake Installation, Operation & Maintenance Manual
P/N 01170006604
Head Rush Technologies products are covered by a number of patents, including
U.S. Patents 8,490,751; 8,851,235; 9,016,435; 8,851,235 and D654,412 & corresponding patents/applica-
tions in the USA and in other countries worldwide.

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TABLE OF CONTENTS
1. SAFETY INFORMATION 7
1.1 Symbols Used in this Manual 7
2. EMERGENCY ARREST DEVICE EAD CONFIRMATION 8
3. SAFETY & INFORMATION LABELS 9
3.1 Location of Safety Labels 9
4. WARRANTY INFORMATION 10
4.1 Warranty Conditions 10
4.2 Customer Responsibility 10
5. SPECIFICATIONS 11
5.1 Introduction 11
5.2 zipSTOP Brake Unit, ZS125-08 12
5.3 zipSTOP Brake Unit, ZSIR150-20A 13
5.4 zipSTOP Brake Trolley, ZS125-08 and ZSIR150-20A 14
6. OPERATING PRINCIPLES 15
6.1 General 15
7. ZIPSTOP BRAKE ASSEMBLY 16
7.1 General 16
7.2 Unpacking the zipSTOP 16
7.3 Long Term Storage 17
7.4 Supplied Parts 18
7.5 General and Additional Parts Required 18
7.6 Redirection Pulleys 19
7.7 Traveler Assembly 19
7.8 Minimum Hardware Requirements 20
7.9 Redirection Line 20
7.9.1 Redirection Line Specifications: ZS125-08/ZS150-20A 21
8. ZIPSTOP BRAKE ASSEMBLY CONFIGURATION 22
8.1 General 22
8.2 Setup Variables, ZS125-08/ZSIR150-20A 22
8.3 Rider Arrival Speed 23
8.4 Rider Weight 23
8.5 Redirection Line Ratio 23
8.5.1 1:1 Ratio 24
8.5.2 2:1 Ratio 25
8.6 POSSIBLE SYSTEM CONFIGURATIONS (INFORMATIVE ONLY) 26
8.6.1 3:1 Ratio 26
8.6.2 Other Configurations 27
8.7 Zip Line Slope 27
8.7.1 Positive Slope Line 28
8.8 Flat Line 28
8.9 Negative Slope Line 29
8.10 Calculating zipSTOP Braking Distances 29
8.10.1 Definition of Terms 30

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8.11 zipSTOP Braking Distance Charts 31
8.12 Configuration Notes 31
8.13 zipSTOP Configuration Worksheet 33
9. ZIPSTOP BRAKE ASSEMBLY INSTALLATION 34
9.1 General 34
9.2 Safety Precautions 34
9.3 Primary Anchor Point 35
9.4 Secondary Anchor Point 35
9.4.1 Position of the Secondary Anchor Point 36
9.5 Redirection and Support Lines 36
9.6 Fitting zipSTOP Brake Unit 37
9.7 Fitting the Brake Trolley 40
9.8 Fitting Type I Pulley 42
9.9 Fitting Type II Pulley 43
9.10 Fitting Redirection Line 43
9.11.1 1:1 Redirection Ratio 44
9.11.2 2:1 Redirection Ratio 46
10. OPERATION OF ZIPSTOP 49
10.1 Safety Precautions 49
10.2 zipSTOP Operation as a Primary Brake 50
10.3 zipSTOP Operation as an EAD 50
10.4 Landing Areas 50
10.5 Operation During Extreme Weather Conditions 51
10.6 Resetting the Brake 51
10.7 Operational Retraction Spring Cycle Limit 52
11. TROUBLESHOOTING 53
11.1 Before You Call 57
12. RECERTIFICATION AND MAINTENANCE 58
12.1 General 58
12.2 Annual Recertification 58
12.3 Maintenance Service Schedule 58
12.4 Daily Inspections 59
12.4.1 Safety Precautions 59
12.4.2 Webbing Wear 60
12.5 Braking Line Replacement Procedure 63
12.6 Brake Trolley Inspection and Maintenance 65
12.7 Brake Unit Casing Inspection 65
12.8 Webbing Line Inspection 66
13. BRAKING DISTANCE CHARTS 67
13.1 How to Read Braking Distance Charts 67
13.2 1:1 Ratio – Metric, ZSIR150-20A 68
13.3 1:1 Ratio – Imperial, ZSIR150-20A 68

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13.4 1:1 Ratio – Metric ZS125-08 69
13.5 1:1 Ratio – Imperial ZS125-08 69
13.6 2:1 Ratio – Metric, ZS125-08 70
13.7 2:1 Ratio – Imperial, ZS125-08 70
13.8 3:1 Ratio – Metric 71
13.9 3:1 Ratio – Imperial 71
14. APPENDIX A: EAD WARRANTY/REGISTRATION FORM 72
14.1 Warranty Registration Form 72
15. APPENDIX B: ACCESSORIES AND REPLACEABLE PARTS 73
15.1 Accessories and Replacement Parts 73
15.2 Brake Trolley Catch Accessory 73
15.2.1 Specifications 74
15.2.2 Composition 74
15.2.3 Mounting/Installation 74
15.2.4 Operation 77
15.2.5 zipSTOP Brake Unit Side Cover Replacement 80
15.2.6 zipSTOP Brake Unit Nozzle Replacement 80
15.2.7 Removing Nozzle Assembly 80
15.2.8 To Refit the Nozzle Assembly: 81
15.2.9 Brake Trolley Bump Stop Replacement 82
15.2.10 Service Life 82
15.3 zipSTOP Pivot Mount 82
15.3.1 Composition 83
15.3.2 Mounting 83
15.3.3 Installation 84
15.3.4 Performance 86
15.3.5 Service Life 86
15.3.6 Inspection Procedures 87
16. APPENDIX C: EXAMPLE INSPECTION LOGS 88
17. MANUFACTURER’S DETAILS 90

IMPORTANT SAFETY NOTICE
Zip Lining is a Dangerous Activity
Read Before Installation & Operation
Failure by the installer or operator to heed any and all instructions, warnings and cautions for the correct
installation, operation, care and maintenance of the zipSTOP may result in serious injury or death.
The zipSTOP Brake assembly, including zipSTOP Brake Unit Model ZB125-08B and ZSIR150-20A, zipSTOP
Brake Trolley Model ZT125-17 and all associated equipment are designed and specified for use in the recre-
ational zip line industry as components of a well designed zip line brake system. Use of the zipSTOP compo-
nents for any purposes other than that intended by the manufacturer is not permitted.
The zipSTOP is designed to be utilized as a Primary Brake or Emergency Arrest Device (EAD). When using the
zipSTOP as a primary brake, the installer MUST utilize an independent EAD to protect against operator error
and third party equipment failure. Design and installation of the zip line, including the complete braking sys-
tem, is the responsibility of the installer or operator.
Owners and Operators of zipSTOP devices are responsible for the safety and supervision of any person using
the zipSTOP and are required to assure that proper installation and operation procedures are followed at all
times. Proper installation requires careful design and planning using zipSTOP and non-zipSTOP components.
Owners and Operators are encouraged to seek the advice of their zip line installer or a proper engineering
professional regarding the instructions in this Manual.
These instructions must be made readily available to the operator at all times. Prior to installation and use, all
owners, installers and operators must have read and shown to have understood all instructions, labels, markings,
and safety information pertaining to the installation, operation, care, and maintenance of the zipSTOP brake, its
component parts, and all associated hardware. Failure to do so may result in equipment damage, serious injury
and death.

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1. SAFETY INFORMATION
1.1 Symbols Used in this Manual
The following safety symbols are used throughout this manual to highlight potential danger to operators and
equipment. One or more precautions may be associated with practices and procedures described within this
manual. Failure to adhere to any precautions highlighted can result in equipment damage, serious injury and/
or death.
Ensure that you read and understand all safety related procedures related to the working environment and the
task you are undertaking.
DANGER
Indicates a hazardous situation exists that, if not avoided, will result in serious injury or death.
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in serious injury or
death.
CAUTION
Indicates a potentially hazardous situation that, if not avoided, may result in injury or equip-
ment damage.
NOTE
Indicates an action that must be taken to ensure personal safety and prevent damage to
property or equipment.
CARE FOR THE ENVIRONMENT
Take care to minimize impact on the environment when carrying out this procedure.

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2. EMERGENCY ARREST DEVICE (EAD) CONFIRMATION
Zip lines using the zipSTOP Brake are required to use both primary and emergency arrest devices functioning
together to arrest the motion of passengers. The EAD must engage with no input from the passenger upon
failure of the primary arrest device.
This form must be initialed by the performing EAD installation technician, signed by a separate party and at-
tached when mailing in the Warranty Registration Form; failure to do so may void your warranty .
I have read this manual prior to zipSTOP installation and use. INITIAL:
I am aware that an approved EAD is required prior to system use. INITIAL:
I certify that an approved EAD has been correctly installed prior to system use. INITIAL:
I have inspected the installation of the EAD and certify its functionality.
SIGNED: DATE:

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3. SAFETY & INFORMATION LABELS
Safety and Information Labels located on the zipSTOP components are not to be removed. Ensure labels are
in place and remain legible at all times.
3.1 Location of Safety Labels
Location of Labels – Brake Unit
Location of Labels – Brake Trolley

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4. WARRANTY INFORMATION
4.1 Warranty Conditions
Manufacturers sole warranty. The zipSTOP Brake assembly will be sold free from defects in materials and
workmanship, excluding field replaceable wear parts, for a period of one (1) year from date of purchase. This
warranty only applies to the original purchaser, and is contingent upon the owner/operator using and main-
taining the device in accordance with the zipSTOP instructions, including the requirement to maintain annual
recertification as described in the Installation, Operation and Maintenance Manual.
THIS WARRANTY IS EXPRESSLY IN LIEU OF OTHER WARRANTIES, EXPRESS OR IMPLIED, AND ANY IMPLIED
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IS HEREBY EXPRESSLY EX-
CLUDED.
The sole remedy for breach of said warranty or for any claim in negligence or strict liability in tort is the repair
or replacement of any defective parts at the discretion of the manufacturer. Such parts claimed to be defec-
tive shall be returned to the Head Rush Technologies Service Center, transportation prepaid, for inspection by
zipSTOP to determine to its satisfaction that said part(s) are defective.
This warranty is null and void if other than genuine parts are used, or if any modifications are carried out to the
zipSTOP Brake assembly or zipSTOP components without the expressed written permission of the manufac-
turer. No person, Agent or Distributor is authorized to give any warranty, other than the one herein expressed,
on behalf of the zipSTOP Company or to assume for it any liability pertaining to such products. The company
makes no warranties in respect to trade accessories or component parts which are not manufactured by the
company, same being subject only to such warranties, if any, as may be made by their respective manufacturers.
4.2 Customer Responsibility
The following items are considered to be the responsibility of the Customer and, therefore, are non-reimburs-
able under the terms of the warranty:
Correct installation of an EAD.
Sucient unmanned testing of the entire system.
Normal maintenance/routine services.
Normal replacement of service items.
Replacements required because of abuse, misuse or incorrect operation of equipment by the installer or
operator.
Field replaceable wear parts such as the nozzle, braking line, quick links, redirection line and pulleys,
brake trolley sacrificial bump stops, and sheaves supplied as zipSTOP branded parts.
Normal wear and tear due to use and exposure.
Strict adherence to the Installation, Operation and Maintenance Manual supplied, manufacturer’s instructions
and advice given by zipSTOP service technicians is also a condition of warranty (see Appendix A: EAD Warran-
ty/Registration Form).

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5. SPECIFICATIONS
5.1 Introduction
The zipSTOP Brake assembly is a controlled braking force device designed specifically for use in the zip line
industry as a Primary or EAD at the end of zip line runs. The zipSTOP caters to a range of rider weights and
approach speeds, and oers a smooth, consistent braking force for all riders. The brake is designed to be
mounted to a primary and/or secondary anchor point to slow the decent of riders on a zip line. The primary
anchor point is exactly what it sounds like; it is the main attachment point for the brake. The secondary an-
chor point is the support point for the redirection lines and pulleys.
The zipSTOP Brake Unit is installed at the end of the zip line, usually on or adjacent to the terminal end. A
Secondary Anchor Point is normally required upstream of the landing area to provide support for the Redi-
rection Line pulleys. Alternately a full-length secondary cable of sucient capacity can be installed to provide
support for the Redirection Line and associated pulleys.
The design of the zipSTOP allows for simple installation, and incorporates both an advanced self-regulating
brake unit and an automatic line reset. The patented braking mechanism delivers smooth deceleration and
is designed to minimize variations in the deceleration rate and stopping distance of both children and adults.
There are no friction parts in the brake mechanism, ensuring reliability remains high while maintenance and
operating costs are kept to a minimum.
Installation, inspection, operation and maintenance must be carried out in accordance with the instructions in
this manual to protect the longevity of the zipSTOP components.
Pictures in this manual are for reference purposes in terms of geometry and proposed redirection setup
configuration only. Mandated EAD may or may not be shown.